Silica Awareness Safety Training for Construction Workplaces

Date: 2026-05-27

Duration: [DURATION] minutes

Presenter: [PRESENTER NAME]

Location: [LOCATION]

Objective

Increase worker awareness of respirable crystalline silica hazards in construction, explain where exposure occurs during dust-generating tasks, and reinforce the controls required to prevent overexposure, protect health, and support compliance with the OSHA construction silica standard.

Introduction

Respirable crystalline silica is a serious construction hazard because the dust particles are small enough to travel deep into the lungs and cause permanent disease. Construction workers can be exposed during excavation, concrete and asphalt cutting, drywall removal, demolition debris handling, drilling, grinding, jackhammering, and similar tasks that disturb silica-containing materials such as sand, concrete, rock, mortar, brick, and stone. OSHA estimates that more than 840,000 workers are exposed to silica levels that exceed the permissible exposure limit annually, and the health effects can include silicosis, lung cancer, COPD, kidney disease, and other serious illnesses. This toolbox talk focuses on recognizing the hazard early and using practical controls every day to keep dust out of the air and out of workers’ lungs.

Presenter Note: Open by connecting silica exposure to the crew’s actual tasks today. Ask workers where they have seen visible dust, slurry, or poor housekeeping on similar jobs, then transition into the health effects and control methods.

Key Points

• 1. Know Where Silica Dust Comes From: Silica is present in many common construction materials, and dust is released whenever those materials are cut, ground, drilled, crushed, chipped, or demolished. High-risk tasks include masonry saw work, handheld drilling, jackhammering, concrete and asphalt cutting, grinding mortar, drywall finishing and sanding, tunneling, abrasive blasting, and heavy equipment operations that fracture silica-containing materials. Workers should assume dust may contain silica unless the task has been evaluated and controlled. [2] [8]
  • Treat visible dust as a warning sign that controls may be inadequate.
  • Do not assume short-duration tasks are safe just because they are brief.
  • Nearby workers can also be exposed, even if they are not performing the task.
• 2. Understand the Health Risks: Breathing respirable crystalline silica can cause silicosis, an incurable and sometimes fatal lung disease. It can also contribute to lung cancer, COPD, kidney disease, and autoimmune disease. Silicosis may develop after weeks of very high exposure or after years of lower exposure, and symptoms may not appear until significant lung damage has already occurred. Early warning signs can include shortness of breath, wheezing, chest tightness, persistent cough, and fatigue. [2] [5] [4]
  • Silicosis is progressive and can worsen even after exposure stops.
  • Smoking adds to lung damage and increases overall respiratory risk.
  • Medical surveillance and prompt reporting of symptoms are critical.
• 3. Follow the Exposure Control Plan and OSHA Requirements: Employers must evaluate tasks that may create silica dust, conduct exposure assessments when required, and implement a written exposure control plan. In construction, a competent person should be designated to implement the plan, inspect job sites, materials, and equipment, and ensure controls are working. Workers should know which tasks are covered by Table 1, where regulated or restricted access areas are located, and when respiratory protection is required. [1] [7] [10]
  • Ask where the written exposure control plan is kept and how workers can review it.
  • Know who the competent person is for the jobsite.
  • Report damaged tools, failed dust controls, or unexpected visible dust immediately.
• 4. Use Engineering Controls First: The most effective way to control silica is to keep dust from becoming airborne or capture it at the source. Use wet methods, integrated water delivery systems, local exhaust ventilation, shrouds, and HEPA-filtered vacuum dust collection systems whenever the task and equipment allow it. Controls must be maintained in good working order, and water flow, hoses, nozzles, filters, and seals should be checked before use. [9] [13] [12]
  • Use water continuously where required and practical.
  • Use vacuum attachments or dust shrouds that match the tool and task.
  • Stop work if the control system is not functioning properly.
• 5. Keep Dust Out of the Breathing Zone and Off the Jobsite: Housekeeping matters because dry sweeping, dry brushing, and compressed air can re-entrain silica dust into the air. Use wet sweeping or HEPA-filtered vacuuming instead. Restrict access to dusty areas, keep other trades away from active silica-generating work, and avoid eating, drinking, or smoking in contaminated areas. Clean dust from tools, clothing, and surfaces before it spreads to other workers or leaves the site. [1] [10] [1]
  • Do not use compressed air unless it is part of an effective dust-capture system or no other feasible method exists.
  • Vacuum clothing with HEPA filtration or change into clean clothes before leaving.
  • Wash hands and face before breaks and before going home.
• 6. Respiratory Protection Is the Last Line of Defense: Respirators are required when engineering and work practice controls cannot keep exposure below the permissible exposure limit or when Table 1 specifies their use. Respirators must be NIOSH-approved and used as part of a proper respiratory protection program. A respirator only protects the worker when it is the correct type, properly fitted, and worn consistently during the exposure period. [1] [9] [7]
  • Do not rely on a respirator instead of dust control.
  • Facial hair can interfere with the seal on tight-fitting respirators.
  • Workers must know how to inspect, don, doff, and seal-check their respirator.

Hazard Identification

Silica exposure hazards on construction sites are often created by routine work that seems ordinary until dust becomes visible. The following hazards are common during excavation, cutting, drilling, demolition, and cleanup activities.

• Cutting, grinding, drilling, jackhammering, or crushing silica-containing materials releases respirable dust into the air.: Workers can inhale fine silica particles deep into the lungs, leading to silicosis, lung cancer, COPD, kidney disease, and other serious respiratory illness. [9]

(Risk: High)

• Dry sweeping, dry brushing, and compressed air cleanup re-suspend settled silica dust.: Dust that had settled on floors, tools, clothing, or surfaces can become airborne again and be inhaled by workers and nearby crews. [10]

(Risk: High)

• Inadequate or poorly maintained wet methods, ventilation, shrouds, or HEPA vacuum systems fail to control dust at the source.: Visible dust may increase, exposure may exceed limits, and workers may need higher-level respiratory protection or may be overexposed without realizing it. [3] [13]

(Risk: High)

• Dust carried on clothing, skin, tools, or vehicles can spread silica beyond the work area.: Workers may contaminate break areas, vehicles, homes, and family members, creating secondary exposure and long-term health risk. [1]

(Risk: Medium)

• Working in enclosed or poorly ventilated areas increases airborne dust concentration.: Dust can accumulate in the breathing zone, increasing the likelihood of overexposure even when controls are in place. [12]

(Risk: High)

Presenter Note: Use the hazard list to prompt workers to name the tasks they perform that create dust. Reinforce that silica exposure is not limited to one trade and that nearby workers can also be affected.

Control Measures

Apply the hierarchy of controls by first eliminating or substituting silica-containing materials where feasible, then using engineering controls to capture or suppress dust at the source, followed by administrative controls such as access restriction, scheduling, and training. Respiratory protection should be used only when higher-level controls cannot fully control exposure or when the standard requires it. This approach is consistent with the construction silica standard and the practical controls identified in the source documents.

• Use wet methods to suppress dust at the source.: Apply water continuously during cutting, drilling, grinding, or breaking operations when the equipment and task allow it. Verify that hoses, nozzles, and water delivery systems are intact and functioning before starting work. [1] [13]
• Use HEPA-filtered vacuum dust collection systems and shrouds.: Attach the correct shroud or dust hood to the tool and connect it to a vacuum with HEPA filtration or equivalent high-efficiency collection. Inspect hoses, filters, and connections regularly and clean or replace components as needed. [1] [12]
• Restrict access to active silica-generating work areas.: Keep unprotected workers, other trades, and visitors out of the dust zone. Post warning signs or barriers when needed and coordinate work so dust-producing tasks are separated from other activities. [1] [6]
• Use approved respiratory protection when required.: Provide NIOSH-approved respirators only when engineering and work practice controls cannot keep exposure below the limit or when Table 1 requires them. Ensure the respiratory protection program includes selection, fit testing, training, and seal checks. [1] [10]
• Use proper housekeeping methods.: Clean with wet sweeping or HEPA-filtered vacuuming. Do not dry sweep, dry brush, or use compressed air unless no feasible alternative exists and the method is controlled to prevent exposure. [10] [1]
• Prevent take-home exposure.: Remove dust from clothing with a HEPA vacuum or change into clean clothes before leaving the site. Shower if facilities are available and do not brush or blow dust off clothing or skin. [1] [5]

Safe Work Procedures

1. Review the task before work begins to determine whether it will generate silica dust and what controls are required. Confirm that the correct tool, attachment, water supply, vacuum, or enclosure is available and functioning. [1]
2. Set up the work area to reduce exposure to others by using barriers, warning signs, scheduling, or distance from other workers whenever possible. [6]
3. Operate tools according to manufacturer instructions and keep dust controls active throughout the task. Stop work if water flow, vacuum capture, or ventilation is not working properly. [13] [12]
4. Clean slurry, settled dust, and tools using wet methods or HEPA-filtered vacuuming before dust dries and becomes airborne. [13] [6]
5. Wash hands and face before eating, drinking, smoking, or leaving the worksite, and change out of dusty clothing before going home. [1] [5]

Presenter Note: Walk through the steps in the same order the crew would perform them on the job: plan, set up, control, clean up, and leave the site without carrying dust home.

Personal Protective Equipment (PPE) Requirements

• Respirator: Use a NIOSH-approved respirator when required by the exposure level, the task, or the control method in use. The respirator must be the correct type for the hazard, properly fitted, and used as part of a full respiratory protection program. Workers should perform seal checks each time they put the respirator on and should not wear tight-fitting respirators with facial hair that interferes with the seal. [1] [7]
  • Follow the site respiratory protection program.
  • Replace damaged or contaminated respirators immediately.
  • Do not modify the respirator or use it outside its intended conditions.
• Eye Protection: Wear safety glasses or goggles to protect against airborne dust, slurry splash, and flying debris generated during cutting, drilling, grinding, or demolition. Eye protection should fit securely and remain in place during the task, especially when wet methods are used. [4]
  • Choose eye protection compatible with the respirator and hard hat.
  • Use side shields or sealed goggles when splash or fine dust is expected.
• Protective Clothing: Wear disposable or washable work clothes that can be cleaned without shaking or brushing dust into the air. If shower facilities are available, shower before leaving the site. Use HEPA vacuuming or change into clean clothing before leaving the work area to prevent take-home exposure. [1]
  • Do not brush or blow dust off clothing.
  • Keep dusty work clothes separate from street clothes.
  • Bag contaminated clothing if required by site procedures.
• Gloves and Skin Protection: Wear gloves when handling abrasive materials, debris, or slurry to reduce skin contact and help keep dust from settling on the hands. Gloves do not replace dust controls, but they support good hygiene and reduce the chance of transferring dust to the face, food, or vehicles. [4]
  • Select gloves appropriate for the task and wet conditions.
  • Wash hands before removing gloves and before breaks.

PPE is important, but it is not the primary control for silica. Use engineering controls and work practices first, then use PPE to fill the remaining gap. PPE only works when it is worn correctly, maintained properly, and used for the full duration of exposure.

Real-World Example or Case Study

A construction laborer spent years cutting and drilling concrete without water suppression or vacuum dust collection, and he was rarely given a respirator. Over time he developed shortness of breath, wheezing, and fatigue after even short periods of work. After he told his doctor about his work history, an x-ray read by a certified Class B reader helped diagnose silicosis. The lesson is clear: uncontrolled dust exposure can cause permanent disease, but the illness is preventable when water, vacuums, respiratory protection, and housekeeping are used correctly. [3] [3]

Presenter Note: Use the case study to make the hazard personal. Ask the crew what controls were missing and what should have been done differently on that job.

Group Discussion

Discuss the following questions:

1. Which tasks on this site are most likely to generate respirable crystalline silica dust, and what controls are we using for each one?
2. What would you do if the water supply, vacuum attachment, or dust control system stopped working during the task?
3. How do we prevent silica dust from leaving the work area and getting into vehicles, break areas, or homes?

Presenter Note: Encourage workers to answer from their own job experience. Reinforce that the best answers are specific, practical, and tied to the actual tools and tasks being used today.

Emergency Procedures

1. Stop the task immediately if dust controls fail, visible dust increases unexpectedly, or equipment malfunctions. Notify the supervisor or competent person so the hazard can be corrected before work resumes. [11]
2. If a worker develops breathing difficulty, chest tightness, wheezing, or other symptoms of overexposure, remove the worker from the dusty area and seek medical evaluation promptly. [3]
3. If silica dust may have contaminated clothing or personal items, clean them using HEPA vacuuming or change into clean clothing before leaving the site to prevent take-home exposure. [1]

Questions and Answers

If you have questions about silica exposure, controls, or respirator use, ask them now. The goal is to make sure everyone understands the task-specific controls before work begins.

• Q: What is respirable crystalline silica?

A: It is the very fine fraction of crystalline silica dust created when materials such as concrete, brick, stone, mortar, sand, and similar products are cut, drilled, ground, crushed, or demolished. These particles are small enough to reach deep into the lungs and cause disease. [9]

• Q: Do I still need controls if the task is short?

A: Yes. Short-duration tasks can still create hazardous silica exposure, and the standard does not provide a blanket exemption just because the task is brief. Use the required controls for the task and verify they are working before starting. [11]

• Q: What is the best way to control silica dust?

A: The best approach is to prevent dust from becoming airborne or capture it at the source using wet methods, local exhaust ventilation, shrouds, and HEPA-filtered vacuum systems. Respirators are important, but they are the last line of defense. [5]

• Q: How do I keep silica dust from going home with me?

A: Vacuum dust from clothing with HEPA filtration or change into clean clothing before leaving the site, shower if facilities are available, and never brush or blow dust off your clothes or skin. [1]

Summary

Recap of main points:

• Silica dust is created by common construction tasks such as cutting, drilling, grinding, jackhammering, demolition, and drywall work, and it can cause permanent lung disease. [2]
• Use engineering controls first, especially wet methods, local exhaust ventilation, and HEPA vacuum dust collection, and keep those systems maintained. [1]
• Use proper housekeeping, access control, and hygiene practices to prevent dust from spreading to other workers, vehicles, and homes. [10]
• Wear the correct PPE, including a NIOSH-approved respirator when required, but remember that PPE is the last line of defense. [1]

Action Items

Specific actions participants should take:

1. Identify the silica-generating tasks you will perform today and confirm the required controls before starting work. [1]
2. Inspect water delivery systems, vacuum attachments, filters, hoses, and seals before use and report defects immediately. [13]
3. Use wet sweeping or HEPA vacuuming for cleanup and keep dust off clothing, skin, and tools. [10]
4. Wear the required PPE correctly and ask for help if you are unsure whether your respirator, eye protection, or clothing is appropriate for the task. [7]
5. Do not eat, drink, smoke, or take dusty clothing home from the jobsite. [1]

Remember: Control silica at the source, protect your lungs, and never take dust home.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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